SEAT Workshop Service and Repair Manuals

Renewing combustion chamber ring seal (Teflon ring seal)   Note The combustion chamber ring seal must always be renewed prior to reinstalling the injector. –  Carefully remove old Teflon ring using suitable tools (e.g. cut open the ring using a razor blade or splay open the ring using a small screwdriver). Then pull forwards to remove. It is important to ensure that the groove and the continuous ridge in the bottom of the groove are not damaged.   Note The injector must be renewed if the groove is damaged. –  Before new Teflon ring is fitted, any combustion residue must be removed from ring groove and injector stem using a clean cloth.   Note The figure shows an injector with „offset connector“.

–  Fit the assembly cone -T10133/5- with a new Teflon seal -1- in the injector -2-.

–  Move the Teflon seal with the assembly bush -T10133/6- towards the mounting cone -T10133/5- until the Teflon seal fits into the groove on the seal. Do not use any lubricants during this procedure.   Note t  The Teflon ring is widened as it is pushed onto the injector. The Teflon ring must therefore be compressed again after it has been fitted. t  The procedure is divided into two steps and is described below. Step 1 of Teflon ring seal calibration (adaption) is carried out using the calibration sleeve -T10133/7-.

–  Install the calibration bushing -T10133/7- on the can until it claps, spinning it (approx. 180°) and exert a little pressure. Rotate the calibration sleeve -T10133/7- in the opposite direction. Step 2 of Teflon ring seal calibration (adaption) is carried out using the calibration sleeve -T10133/8-.

–  Install the calibration bushing -T10133/8- on the can until it claps, spinning it (approx. 180°) and exert a little pressure. Rotate the calibration sleeve -T10133/8- in the opposite direction. –  Fit new O-ring on injector. Lubricate O-ring lightly with clean engine oil before installing. –  The teflon ring must not be lubricated.

–  Use supplied nylon brush -T10133/4- to thoroughly clean holes for injectors in cylinder head prior to installing injectors.   Note t  Do not apply grease or oil to the Teflon seal of the injector. t  Make sure that there is no cleaning fluid or oil in the holes in the cylinder head when installing the injectors. –  Push injector by hand as far as it will go into aperture in cylinder head (do not use oil or grease). Ensure that the injector is properly seated in the cylinder head.   Note t  It should be possible to insert injector easily. If necessary wait until the combustion chamber ring seal has contracted sufficiently. t  Ensure for the correct installation position of the injectors in the cylinder head.

t  If the injector cannot be pushed in by hand, use puller -T10133/2A--2- with striker -T10133/3- to insert injector. –  The remaining installation steps are carried out in the reverse sequence. The following points must always be observed: l  Coat O-rings of high-pressure injectors with clean engine oil to facilitate insertion into fuel rail. l  Replace all the gaskets. l  Fuel rail must be positioned on injectors and pressed in evenly. l  Install the intake manifold together with the fuel rail, 1.8 litre engine (CDHA, CDHB) → Chapter; 2.0 litre engine (CDND) → Chapter.